Classifications

• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L27/00—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Compositions of derivatives of such polymers
  • C08L27/02—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Compositions of derivatives of such polymers not modified by chemical after-treatment
  • C08L27/04—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Compositions of derivatives of such polymers not modified by chemical after-treatment containing chlorine atoms
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F261/00—Macromolecular compounds obtained by polymerising monomers on to polymers of oxygen-containing monomers as defined in group C08F16/00
  • C08F261/02—Macromolecular compounds obtained by polymerising monomers on to polymers of oxygen-containing monomers as defined in group C08F16/00 on to polymers of unsaturated alcohols
  • C08F261/04—Macromolecular compounds obtained by polymerising monomers on to polymers of oxygen-containing monomers as defined in group C08F16/00 on to polymers of unsaturated alcohols on to polymers of vinyl alcohol
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L27/00—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Compositions of derivatives of such polymers
  • C08L27/02—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Compositions of derivatives of such polymers not modified by chemical after-treatment
  • C08L27/04—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Compositions of derivatives of such polymers not modified by chemical after-treatment containing chlorine atoms
  • C08L27/06—Homopolymers or copolymers of vinyl chloride
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L29/00—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an alcohol, ether, aldehydo, ketonic, acetal or ketal radical; Compositions of hydrolysed polymers of esters of unsaturated alcohols with saturated carboxylic acids; Compositions of derivatives of such polymers
  • C08L29/02—Homopolymers or copolymers of unsaturated alcohols
  • C08L29/04—Polyvinyl alcohol; Partially hydrolysed homopolymers or copolymers of esters of unsaturated alcohols with saturated carboxylic acids
• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
  • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
  • D01F6/44—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from mixtures of polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds as major constituent with other polymers or low-molecular-weight compounds
  • D01F6/48—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from mixtures of polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds as major constituent with other polymers or low-molecular-weight compounds of polymers of halogenated hydrocarbons
• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
  • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
  • D01F6/44—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from mixtures of polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds as major constituent with other polymers or low-molecular-weight compounds
  • D01F6/50—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from mixtures of polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds as major constituent with other polymers or low-molecular-weight compounds of polyalcohols, polyacetals or polyketals

Definitions

• ABSTRACT A method for producing fibers and films comprising emulsion polymerizing a polyvinyl alcohol derivative having sulfone or sulfate group with a chlorinecontaining vinyl monomer, adding the thus formed emulsion to a matrix of polyvinyl alcohol and then coagulating the mixture into a film or fiber.
• the resulting polymeric compositions are composed of polyvinyl alcohol, the sulfone or sulfate-containing polyvinyl alcohol and the chlorine containing vinyl polymer, in which a part of the chlorine-containing vinyl polymer is grafted onto the polyvinyl alcohol derivative.
• the emulsions used possess excellent stability and the films and fibers therefrom possess excellent heat resistance.
• the present invention relates to fibers and films having excellent heat resistance, mechanical properties and luster prepared 'by conventional wet or dry processes. More particularly, the fibers and films are prepared from a composition consisting of an aqueous emulsion, which consists either of a polymer or copolymer obtained by polymerizing vinyl chloride and/or vi nylidene chloride or vinyl chloride and/or vinylidene chloride and another monomer in the presence of polyvinyl alcohol derivatives containing a sulfone or sulfate group and a catalyst, in the substantial absence of an emulsifier, and a matrix consisting essentially of polyvinyl alcohol.
• an aqueous emulsion which consists either of a polymer or copolymer obtained by polymerizing vinyl chloride and/or vi nylidene chloride or vinyl chloride and/or vinylidene chloride and another monomer in the presence of polyvinyl alcohol derivatives containing a sulfone or sul
• polyvinyl chloride polyvinylidene chloride
• polyvinyl alcohol polyvinyl alcohol
• PVC polyvinylidene chloride
• PVdC polyvinyl alcohol
• PVA polyvinyl alcohol
• the expression polyvinyl chloride may represent polyvinyl chloride and/or polyvinylidene chloride or a copolymer with vinyl chloride and/or vinylidenech'loride.
• the fibers and filmsprepared by the above process are adequately hydroscopic and excellent in softness and antiinflammability because they contain both hydrophobic PVC and hydrophilic PVA as the major con stituents. But, on the other hand, those properties, such as, heat resistant, mechanical and luster are inevitably lowered due to the large amount of emulsifying agent which is used in the emulsion polymerization and remains as a contaminant in the resulting fibers and films.
• an anionic emulsifying agent isgenerally used which is rather unstable when heated.
• the thermal decomposition products therefrom accelerate thermal decomposition of the PVC which is poorly heat resistant. This leads to discoloration of the produced fibers and films.
• the low molecular-weight emulsifying agent that is contained as one of the constituents in the processed fibers and films can deleteriously affect the mechanical properties, transparency, and luster of the products.
• the presence of such a low molecular substance may promote the nonuniformity in the fine structure of the product.
• the aqueous emulsion used in the present invention can be prepared essentially without the addition of any emulsifying agent by using, in addition to a polymeriza- I tion catalyst, a PVA derivative containing a sulfone or sulfate group in the emulsion polymerization of the vinyl chloride and/or vinylidene chloride or a mixture of vinyl chloride and/or vinylidene chloride and another monomer.
• the emulsion thus obtained is mechanically stable and contains particles having a small particle size.
• the present invention thus relates to fibers and films which are prepared by mixing the above mentioned PVC emulsion with an aqueous PVA solution or ,an aqueous mixture of PVA with another water soluble high molecular substance to obtain a highly stable spinning or film-making liquid from which spun fibers or films are prepared by a wet process, and by applying thermal stretching or other thermal treatments to the fibers and films according to known processes for spinning and film-making.
• the present invention applies a PVA derivative containing a sulfone or sulfate group in the emulsion polymerization.
• the PVA derivative of the present invention acts not only as a dispersion agent, but also, as an emulsifying agent, to yield an aqueous emulsion for spinning fibers or film-making which is stable both mechanically and in storage and contains particles of a small size.
• the spinning composition of the present invention is composed of:
• chlorine-containing vinyl monomers such as, vinyl chloride and vinylidene chloride
• the polymerization degree of PVA is 900 to 2500 and the polymerization degree of PVA derivative is to 1000.
• the present process is carried out by emulsion polymerizing components (a) and,(b) with (c) or (c') in an aqueous emulsion and adding (d) to it.
• the above mixture may beformed into fibers and films by conventional wet or dry processes.
• composition as spun is composed of PVA, PVA
• a substance called sulfuric acid esterified polyvinyl alcohol which is produced, for example, by adding one part of PVA powder to 20 parts of aqueous solution containing 30% by weight of sulfuric acid and by weight of sodium sulfate, and by heating at 80C for 2 hours, and is expressed by the following formula,
• X stands for a hydrogen or an alkali metal atom, such as sodium and potassium
• m and n stand for arbitrary integers. (I00 g m n s 1000, m/(m-l-n) X 100 0.5 to
• the sulfone or sulfate group content of the PVA derivatives employed in the present invention should be within the range described below.
• the effect is insufficient for a sulfone or sulfate group content of less than 0.5% by moles.
• the higher the percentage the finer are the particles of the emulsion and the lower the 4 viscosity.
• a sulfone or sulfate content in the range of from about 0.5 to 20% by moles is best.
• the content should be preferably in the range of from about 0.7 to 10% by moles.
• the object of this invention can be fully attained within these ranges.
• the viscosity of the aqueous emulsion is remarkably affected by the degree of polymerization of the PVA derivative used in the emulsion polymerization that contains the sulfone or sulfate groups.
• the viscosity of the aqueous emulsion is also related to the viscosity of the spinning liquid which is prepared by adding an aqueous solution of PVA alone or a mixture of PVA with another water soluble high molecular substance to said aqueous emulsion.
• the higher is the viscosity of the emulsion the more viscous is the spinning liquid.
• the favorable degree of polymerization of the PVA derivatives containing sulfone or sulfate groups in the present invention is from about lOO to 1000, preferably from about 200 to 700.
• the polymerization degree of the PVA derivative means m n defined on pages 7 and 8. The same applies to the film-making liquid of this invention.
• the appropriate amount of the PVA derivatives containing sulfone or sulfate groups to be used in the present invention differs depending on the sulfone or sulfate content and the degree of polymerization of the PVA derivatives.
• the amount should be from about 1.5 to 20%, and preferably from about 1.5 to 10% by weight, based on the weight of the polymer components in the aqueous emulsion. Only a minimal effect can be expected with less than 1.5%, and, for larger values exceeding this range, the viscosity of the aqueous emulsion becomes excessively high.
• the filterability of the spinning liquid that is prepared by adding an aqueous solution of PVA as the matrix to the aqueous emulsion can be improved by using a small amount of an emulsifying agent in or after the preparation of the aqueous emulsion. For this reason, a small amount of an emulsifying agent may be used in parallel to the use of PVA derivatives which contain the sulfone or sulfate groups.
• the emulsifying agents used in this invention include a single member or a combination of more than two members of anionic surfactants, such as, sulfates of higher alcohols, alkylarylsulfonates, alkylsulfosuccinate and salts of fatty acids, and further a mixture of the above emulsifying agents with a non ionic surfactant, such as, polyethyleneglycolalkyl ether, polyethyleneglycol alkylaryl ether and polyethyleneglycol fatty acid ester.
• anionic surfactants such as, sulfates of higher alcohols, alkylarylsulfonates, alkylsulfosuccinate and salts of fatty acids
• non ionic surfactant such as, polyethyleneglycolalkyl ether, polyethyleneglycol alkylaryl ether and polyethyleneglycol fatty acid ester.
• the polymerization catalysts of this invention include water soluble peroxides, such as, potassium persulfate, ammonium persulfate and hydrogen peroxide which are used either alone or in the form of a redox catalyst that is formed by the parallel use of a reducing agent such as sodium hydrogen sulfite, ferrous sulfate, and lor d-ascorbic acid.
• water soluble peroxides such as, potassium persulfate, ammonium persulfate and hydrogen peroxide which are used either alone or in the form of a redox catalyst that is formed by the parallel use of a reducing agent such as sodium hydrogen sulfite, ferrous sulfate, and lor d-ascorbic acid.
• the amount of the catalyst is 0.02 to 1% by weight to the polymeric monomer when the peroxide is used in out using one or more members of the chlorine-containing vinyl monomers alone or a mixture of the same with another vinyl monomer selected from the group consisting of acylonitrile, styrene, vinyl acetate, propionic acid vinyl ester and acrylic acid ester.
• the amount of the other vinyl monomer is usually not more than 15% by weight on the base of the total
• a PVA derivative containing sulfone groups was prepared by saponifying sodium vinylsulfonate-vinyl acetate copolymer containing 2.0% by moles of sodium vinylsulfonate, having a saponification degree of 98.5% by moles and degree of polymerization of 350.
• the aqueous emulsions. produced contained fine particles and exhibited good mechanical stability as shown in the table below.
• PVA having a polymerization degree of 350 and a saponification degree of 99.0% by moles was used instead of the PVA derivative containing sulfone groups and the operation throughout the emulsion polymerization was the same.
• Amount of emulsifying agcnt (part) A B A B A B B good Coarse Gelatiniz ed good stable good good good good good good good good good good good good good good good good good good good good good good good A Material of this invention B: Reference monomers. When the amount is beyond 15% by weight, the particle size of the emulsion will be coarse, and the mechanical stability of the emulsion tends to lower, and also the spinning liquid obtained by the addition of PVA as matrix lowers in its stability.
• an aqueous emulsion which is prepared by emulsion polymerization for example, of vinyl chloride in an aqueous solution of a PVA derivative that contains sulfone or sulfate groups is destroyed by a freezing treatment and a solid material is separated (referred to as homopolymer plus graft material). Extraction of this material with hot water and the resulting dried residue with tetrahydrofuran leaves a graft polymer which is insoluble in hot water and tetrahydrofuran.
• the emulsion prepared by the process of this invention exhibits high mechanical stability as shown below and can be stored for a long period of time.
• Storage stability of the emulsion was designated as good when substantially no change was observed in viscosity, pH and appearance for a week at 30C.
• Viscosity of the emulsion was measured with a rotatory viscosimeter at 25C.
• the process of this invention even without use of an emulsifying agent, provided emulsions which were unexpectedly excellent in both me chanical stability and storage stability. Further, when a small amount of emulsifying agent was applied, the particle size was finer'than those in references prepared under identical conditions. It is evident that the present invention can provide emulsions much more stable than those from conventional processes.
• the matrix of this invention can be prepared from either PVA alone or a mixture of PVA with another water soluble high molecular substance.
• the applicable high molecular substances include synthetic high polymers, such as, polyacrylamides andmethylolated polyacrylamides and natural high polymers, such as, starch, hydroxyethyl cellulose and methylcellulose, and the amount thereof to be mixed must be less than 50% by weight to the PVA.
• saponification degree of PVA used as matrix may be respectively 900 to 2500 and more than 95 mole depending on the kind of the water emulsion or the mixing proportion of the water emulsion to the matrix PVA.
• the matrix PVA is added to the water emulsion as 14 to 20 weight aqueous solution.
• aqueous emulsion prepared in accordance with the present invention by the emulsion polymerization of polymerizable monomers of which the most part is of chlorine-containing monomers in an aqueous solution of the PVA derivative containing sulfone or sulfate groups can be thoroughly mixed with the matrix component, hold excellent stability as shown by the time variation of viscosity, and also possesses good filterability and spinnability.
• the water soluble high polymer of which PVA is the most dominant component-to be added as the matrix to the aqueous emulsion should be added in the amount of from about 40 to 250% by weight to the polymer components in the aqueous emulsion, to obtain a good result. If the amount of matrix exceeds this value, the emulsion becomes too dilute to be continuous, while the effect of the matrix becomes incomplete for an amount of matrix below the lower limit of the range.
• the spinning-liquid prepared according to the process of this invention is then extruded in the form of fiber or film into a coagulating solution of sodium sulfate, following the ordinary process of emulsion spinning, and the products are treated, if necessary, by wet thermal treatment, washing with water, drying, stretching, thermal treatment and the conventional acetal treatment.
• the products thus obtained exhibit better mechanical properties, heat resistance and have more luster with a'transparent appearance than similar products prepared by the known processes.
• they can be dyed with any of the basic, dispersion and sulfide dyes, supplying coloredv product with improved vividness.
• the PVA derivative which contained sulfone groups and had 98.5% by moles of saponification degree and 350 of polymerization degree and was obtained by saponification of a sodium vinylsulfonate-vinyl acetate copolymer containing 2.0% by moles of sodium vinylsulfonate, 0.26 part of potassium persulfate, 460 parts of desalted
• PVC emulsions obtained of which the solid concentrations were 31.5 and 31.8% by weight (polymer components were 31.5 and 31.5% by weight), showed excellent stability of the emulsion:
• the spinning liquid above was spun in an aqueous solution of sodium sulfate to prepare fibers, submitted to wet thermal treatment, washing with water, a drying, a stretching, a thermal treatment and f1- nally an acetal treatment with formaldehyde to obtain fibers of 2 denier.
• the heat resistance of the fibers was comparatively tested with the reference fibers which were prepared in the same process except that, in place of the PVA derivative containing sulfone groups, a PVA of the degree of polymerization 350 and the degree of saponification 99.0% by moles was used and the emulsifying agent was increased to 9.6 parts. Results are shown in the following table.
• Emulsifying agent (part) Remark The coloring by heat was expressed by the whiteness observed after thermal treatment in a Geer type Ageing tester. Larger values represent better results.
• the known process which employs PVA provides products of more remarkable heat coloration than the process of the present invention does where no emulsifying agent is used, and the latter process, even when a small amount of an emulsifying agent is applied, provides products of more excellent heat resistance than conventional processes do.
• the uniform fine structure of thecross section of the fibers is an achievement of this investigation.
• observation with an optical microscope does not, but careful observation with an electron microscope does show a dual structure formation skin and core as distinct as in the PVA fibers produced by the wet spinning process.
• the fibers produced by the process of this invention have a uniform cross-sectional structure and are lustrous due to the absence of the emulsifying agent in the composition so that dyed products therefrom show extremely clearer tones of color relativetto products obtained by conventional methods and whichhave a dual structure.
• conventional additives such as, various pigments, frosting agent toremove luster, stabilizer, or a fire-retardant,
• the spinning liquid of this invention thus obtained was compared with respect to stability with reference liquids for spinning, including one in which the PVA derivative containing sulfone groups was replaced by PVA, and ones in which 0.96 and 9.6 parts of sodium laurylsulfate were used as an emulsifying agent and each PVC emulsion was polymerized in the same manner. Results are shown below.
• This Reference Reference Reference invention (1) (2) Emulsifying agent 0 0 0.96 part 9.6 parts Storage stability Good Gelatin Good Good of PVC emulsion ized Mechanical stability of PVC emulsion 240 min. 1 min. 4 min. 240 min.
• the present invention provides fibers and films, which are prepared from the material by emulsion, spinning and film-making process respectively, and have better heat resistance, mechanical properties and luster than those prepared by conventional known processes.
• the material is composed of a water soluble high molecular substance where PVA is the major constituent and those substances which include a chlorine-containing polymer, such as, PVC and PVdC, or a copolymer from these chlorine-containing monomers or a copolymer of said chlorine containing monomers with other monomers.
• the fibers of this invention obtained by the above process can be spun into yarn by ordinary methods and used for producing various fiber products including non-woven cloth in the same manner as for other general-purpose synthetic fibers.
• EXAMPLE 1 A mixture consisting of 10.9 parts of a sulfone group containing PVA derivative of the degree of saponification 98.5% by moles and the degree of polymerization 350 which had been obtained by saponifying sodium vinylsulfonatevinyl acetate copolymer containing 2.0% by moles of sodium vinylsulfonate, 0.26 part of potassium persulfate, 460 parts of desalted water and 218 parts of vinyl chloride was placed in an autoclave, and the polymerization was carried out under stirring for 8 hours at the temperature range where the maximum was 50C.
• the polyvinyl chloride emulsion thus obtained contained 31.5% by weight of solid matter (or 31.5% by weight of polymer components inthe emulsion), and the physical properties were as follows: the viscosity at 25C was 7.0 cp, average diameter of particles was 154m mechanical stability was greater than 4 hours, the grafting efficiency was 18.6% and the storage stability was such that no change was observed after 6 months of storage.
• the stability of the spinning liquid in reference (3) was expressed in terms of viscosity. that is 12 sec. immediately after preparation, and 15 see. after 24 hours, increasing gradually with the elapse of time, while the viscosity of the spinning liquid of this invention remained constant, i.e., 1 1 see. after the preparation and even after 24 hours.
• the viscosity was expressed by the time in seconds during which a steel ball of l/8 inch diameter falls a distance of 30 cm in the spinning liquid at C.
• the spinning liquids of the present invention and of the reference (3) were extruded after filtration into an aqueous 350 g/l solution of sodium sulfate to make fibers and then introduced into a 300 g/l bath of sodium sulfate at C for the wet thermal treatment, then washed with water and dried, stretched at 150C and subjected to a thermal treatment at 230C.
• the fibers thus produced were treated for 30 min. at 70C to be converted into acetal in a bath which contained 5.0 parts of formaldehyde, 15 parts of sulfuric acid, 10 parts of sodium sulfate and 70 parts of water.
• Table 1 shows, with respect to the 2 denier fibers of this invention, mechanical properties, uniformity of cross section, luster. dycability, heat resistance and dry-hot contraction.
• EXAMPLE 2 A spinning liquid was prepared by adding a 15% aqueous solution of PVA as a matrix to the PVC emulsion in Example 1 in the same manner as in Example 1 so that the PVA amounted to 30, 40, 100, 200, 250 and 300% by weight to the total polymer components in the emulsion.
• the fibers from the spinning liquid were stretched and thermally fixed as in Example 1 and converted into the acetal to produce fibers of 5 denier.
• the object of this invention can be attained only in the range of PVA as matrix extending from about 40 to 250% by weight to the total polymer components in the emulsion.
• EXAMPLE 3 A mixture consisting of 5.5 parts of a sulfone group containing a PVA derivative of the degree of polymerization 200 and the degree of saponification 98.0% by moles which had been obtained by saponifying a sodium allylsulfonatevinyl acetate copolymer containing 10.0% by moles of allylsulfonic acid, 1.92 parts of sodium dodecylbenzenesulfonate, 0.30 part of ammonium persulfate, 196 parts of vinyl chloride, 22 parts of vinyl acetate and 460 parts of desalted water was placed in an autoclave and the polymerization was carried out for 6 hours under stirring at temperatures up to 50C.
• the emulsion thus obtained of vinyl chloridevinyl acetate copolymer contained solid matter amounting to 31.8% by weight (31.5% by weight of the total polymer components), and possessed a viscosity of 9.1 cp at 25C, the average particle size being 44
• the mechanical stability was greater than 4 hours and the storage stability was so excellent that no change in appearance was observed after a lapse of 6 months.
• the stability of the spinning liquid obtained in the above procedure was compared with that of the reference spinning liquid which had been prepared from the vinyl chloride-vinyl acetate copolymer emulsion using PVA instead of a PVA derivative containing sulfone groups and 9.6 parts of an emulsifying agent since 1.92 parts of the emulsifying agent was not sufficient to give the necessary mechanical stability to the emulsion and a satisfactory spinning liquid.
• the stability was expressed by the viscosity of the spinning liquid; thus, the viscosity of the reference spinning liquid increased with time was 12 and 15 sec., immediately and 24 hours, respectively, after the preparation, while the spinning liquid of this invention maintained a stability of 10.5 sec. for as long as 24 hours, thereby demonstrating extremely excellent stability.
• the spinning liquid after filtration, was spun into fibers in an aqueous solution containing 350 g/l of sodium sulfate at 45C, which were then treated by wet thermal treatment in a bath of 300 g/l of sodium sulfate at C, washed with water, dried, stretched at C and thermally treated at 230C.
• the fibers thus obtained were converted into the acetal by being treated for 30 min. in a bath consisting of 5 parts of formaldehyde, 15 parts of sulfuric acid, 10 parts of sodium sulfate and 70 parts of water.
• the heat resistance of the 2 denier fibers of this invention was comparatively examined with that of the reference fibers prepared in the similar process.
• the heat resistance of the fibers of this invention was so excellent that thermal discoloration and thermal contraction were far less and the effect'was exhibited more remarkably at temperatures above 150C.
• the fibers of the present invention showed further improved properties than the reference fibers did, as is shown in Table 3.
• EXAMPLE 4 A mixture consisting of 10.9 parts of a PVA derivative containing 1.0% by moles of sulfone groups and of the degree of polymerization 300 which had been prepared by sulfonating with sodium hydrogen sulfite, completely saponified PVA as the PVA derivative containing sulfone groups, 0.96 part of sodium dodecylbenzenesulfonate, 0.26 part of potassium persulfate, 460 parts of desalted water, and 218 parts of vinylidene chloride was placed in an autoclave, and polymerization was carried out for 10 hours at 45C.
• the emulsion of polyvinylidene chloride contained 31.4% by weight of solid matter (31.2% by weight of the polymer components). The viscosity was 12.3 cp at 25C, and the average particle size was 85 mp. Mechanical stability exceeded 4 hours and the storage stability was so large that no change was observed after 6 months.
• the said spinning liquid after filtration was spun into a 350 g/l aqueous solution of sodium sulfate to prepare fibers.
• the fibers were then introduced into a 300 g/l bath of sodium sulfate at 90C for wet thermal treatment, washed with water, dried, stretched at 150C and finally thermally treated at 230C.
• the fibers thus obtained were converted into the acetal by being treated for 30 min. at 70C in a bath consisting of 5 parts of formaldehyde, 15 parts of sulfuric acid, 15 parts of sodium sulfate and 70 parts of water.
• the fibers of the present invention thus prepared exhibited particularly excellent properties in heat resistance, mechanical properties, luster and dyeability.
• EXAMPLE 5 A mixture consisting of 10.9 parts of a sodium salt of PVA converted into the sulfuric acid ester of the degree of polymerization 500 and containing 5.0% by moles of sulfate groups produced by treating a completely saponified PVA with sulfuric acid, 0.30 part of ammonium persulfate, 460 parts of desalted water, 153 parts of vinyl chloride and 65 parts of vinylidene chloride was placed in an autoclave and the polymerization was carried out for 7 hours under stirring at temperature up to 50C.
• the copolymer emulsion of poly (vinyl chloride-vinylidene chloride) contained 31.6% by weight of solid matter.
• Viscosity was 9.7 cp at 25C and average particle diameter was 148 mg.
• the mechanical stability was more than 4 hours and the storage stability was so large that no change was observed even after a lapse of 6 months.
• the spinning liquid after filtration, was extruded through a 0.2 mm slit into a 350 g/l aqueous solution of sodium sulfate to make films, the films prepared were passed through a bath of a saturated solution of sodium sulfate of which the temperature was gradually elevated from 70 to C, and then through a g/l aqueous solution of sodium sulfate at 30C, cooled and washed with cold water. Further, the product was stretched to twice its length at 100 to C.
• the films thus prepared were transparent and excellent in mechanical properties.
• the films of the present invention was less colored by heat than the films for reference which were vious ones in transparency, mechanical properties and heat resistance
• EXAMPLE 6 A mixture consisting of 17.4 parts of a PVA derivative containing sulfone groups of the degree of polymerization 350 and the degree of saponification 99.5% by moles which had been prepared by saponifying so dium methallylsulfonate-vinyl acetate copolymer containing 3.5% by moles of the sodium methallylsulfonate, 0.1 part of potassium persulfate, 0.05 part of sodium hydrogen sulfite, 205 parts of vinyl chloride, 13 parts of propionic acid vinyl ester and 420 parts of desalted water was placed in an autoclave and the polymerization was carried out for 3 hours under stirring at a temperature up to 50C.
• the resulting mixture was thoroughly mixed, kept at 80C and debubbled, to prepare a spinning liquid.
• the polymer component in the matrix amounted to 150% by weight to the polymer components in the emulsion.
• the viscosity of the spinning liquid of this invention was 16 sec. immediately after preparation, and the same value remained even after 24 hours, holding excellent stability.
• the said spinning liquid was treated successively by spinning, wet thermal treatment, drying stretching, thermal treatment and converting into acetal.
• the fibers obtained exhibited excellent properties in heat resistance, mechanical properties, luster and dyeability.
• EXAMPLE '7 The 2 denier staple fibers (the cut length 38 mm) of this invention obtained in Examples 1 and 3 were processed into spun yarn with cotton yarn number 20 and number of twist 15/inch using a Shirley Minature Spinning Plant (supplied by Platt International Ltd). The yarn strength of the obtained spun yarns was 0.463 kg and 0.450 kg for the yarns in Examples 1 and 3, respectively.
• the spun yarns prepared from the fibers of this invention were more excellent in heat resistance, mechanical properties, luster and dyeability than the yarns from the fibers for reference.
• the yarn strength ofspun yarn was estimated by 11S L1067 (corresponding to ASTM D 2256-69).
• EXAMPLE 8 Using the spun yarn with cotton yarn number 20 of this invention prepared in Example 7, plain woven clothes were made with number of warps 55/inch and number of wefts /inch having a weight of 130 g/m The tensile strengths of the clothes were as follows:
• Example Reference 3 Example Reference 1 in Example 1 3 in Example 3 Longitudinal 27.6 Kg 23.4 Kg 26.2 Kg 23.0 Kg Lateral 48.0 40.8 45.8 40.2
• the clothes produced from the spun yarn of this invention exhibited better properties in heat resistance, mechanical properties, luster and dyeability, as they are characteristic to the fibers of this invention, than those prepared from the reference fibers in Examples 1 and 3. Further, clothes woven using the spun yarn from the fibers in Example 3 that contained the fire-retardant showed high efficiency in avoiding inflammation and passed the vertical direction test in accordance with DOCFF 3-71. Note: The tensile strength of clothes was measured according to 11$ L1068 (corresponding to ASTM Dl682-64).
• An aqueous emulsion containing a polymeric composition comprising (A) polyvinyl alcohol of polymerization degree from 900 to 2500, (B) polyvinyl alcohol derivative of polymerization degree from 100 to 1000 containing 0.5 to 20% by moles of sulfone or sulfate groups and (C) chlorinefcontaining vinyl polymer, a part of the chlorine-containing vinyl polymer being grafted on to the polyvinyl alcohol derivative, the contents of said polyvinyl alcohol being 40 to 250% by weight of (B) and'(C), and the content of said polyvinyl alcohol derivative being 1.5 to 20% by weight of (B) and (C), and the content of said chlorine-containing vinyl polymer being to 98.5% by weight of (B) and (C), the graft efficiency of said composition being from about 5 to 50%.
• polyvinyl alcohol containing sulfone or sulfate groups is a polyvinyl alcohol derivative having sulfone groups prepared by saponifying the copolymer which is produced by copolymerization of vinyl acetate with a polymerizable monomer having sulfone groups selected from the group consisting of vinyl sulfonic acid, allylsulfonic acid, methallylsulfonic acid and the salts including sodium salts and potassium salts thereof.
• component (B) is a polyvinyl alcohol derivative having sulfone groups prepared by a reaction in which polyvinyl alcohol is treated with bromine or iodine followed by heating in an aqueous solution of sodium hydrogen sulfite.
• polyvinyl alcohol containing sulfone or sulfate groups is a polyvinyl alcohol converted into a sulfuric acid ester which is prepared by heating polyvinyl alcohol in a concentrated aqueous solution of sulfuric acid.
• chlorinecontaining vinyl polymer is a polymer formed from chlorine-containing vinyl monomers selected from the group consistingof vinyl chloride, vinylidene chloride and combinations thereof, or a copolymer formed from the said chlorine-containing vinyl monomer with another polymerizable vinyl monomer.
• T emPlslon of clalm Wherem the chlorme' 12.

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• Chemical & Material Sciences (AREA)
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• Medicinal Chemistry (AREA)
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• Organic Chemistry (AREA)
• General Chemical & Material Sciences (AREA)
• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
• Artificial Filaments (AREA)
• Addition Polymer Or Copolymer, Post-Treatments, Or Chemical Modifications (AREA)
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• 1972
  • 1972-11-21 JP JP47116207A patent/JPS5130906B2/ja not_active Expired
• 1973
  • 1973-11-19 US US416801A patent/US3925290A/en not_active Expired - Lifetime
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• 1974
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